DETAIL SPECIFICATION CABLES, RADIO FREQUENCY, FLEXIBLE AND SEMIRIGID GENERAL SPECIFICATION FOR

Transcription

1 INCH-POUND 04 May 2011 SUPERSEDING 19 August 2005 DETAIL SPECIFICATION CABLES, RADIO FREQUENCY, FLEXIBLE AND SEMIRIGID GENERAL SPECIFICATION FOR This specification is approved for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers flexible and semirigid cables with solid and semisolid dielectric cores, with single, dual and twin inner conductors. Cables covered by this specification are primarily intended for use as transmission lines to conduct energy in a simple power transfer continuously or intermittently. In general, these cables are designed for low-loss, stable operation from the relatively low frequencies through the higher frequencies in the microwave and radar regions of the frequency spectrum. Cables may also be used as circuit elements, delay lines or impedance matching devices. These cables are supplied under a reliability assurance program as specified in section Classification. Cables are of the following types (see 6.2) Cable types Flexible, coaxial single conductor. A flexible coaxial cable is constructed of a single inner conductor covered by a flexible low-loss, RF dielectric core material, which is then surrounded by a braided outer conductor(s), with the whole covered by a protective covering. In some cases this is covered by an extra braided armor for use in extremely abusive applications. Each element of the cable is designed to contribute to the requirements of the finished product Semirigid, coaxial single conductor. Semirigid coaxial cables are constructed of a single inner conductor covered by a flexible low-loss RF dielectric core material, which is then surrounded by a solid, continuous, metallic outer conductor. Comments, suggestions, or questions on this document should be addressed to DLA Land and Maritime, Attn: VAI, P.O. Box 3990, Columbus, OH , or ed to RFConnector@dla.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at AMSC N/A FSC 6145

2 Two-conductor. Individual dielectric cores of two-conductor cables are to meet the requirements of solid or semisolid dielectric cores. One strand of one of the inner conductors are to be coded for identification and be visible without disturbing the stranding. That is, if all of the strands of the inner conductors are coated, then one strand is to be bare; or if all of the strands are bare, then one strand is to be coated. a. Twin. Twin cables are to be constructed of individual inner conductors within individual dielectric cores within a common outer conductor, or may have individual inner conductors within a common outer core that may be filled-to-round. b. Dual. A dual cable is to be constructed of individual coaxial cables enclosed within a common outer conductor Triaxial. Triaxial cables are constructed the same as regular coaxial cables except for an additional interlayer of dielectric material over the outer conductor, over which is laid an extra shield, with the whole covered by a protective covering. 1.3 Part or Identifying Number (PIN). The PIN consists of the letter M followed by the specification number, the associated slash sheet number and the sequentially assigned dash number or "RG" number. M17/ 60 - RG142 Example of existing RG number - M17/28-RG058 Example of new number - M17/ RG or dash number Specification sheet number Basic specification number 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4 or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3, 4 or 5 of this specification, whether or not they are listed. 2.2 Government documents Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. FEDERAL STANDARDS FED-STD-228 FED-STD Cable and Wire, Insulated; Methods of testing - Rubber, Sampling and Testing 2

3 DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-I-631 MIL-Y-1140 MIL-DTL-5624 MIL-DTL MIL-PRF MIL-PRF MIL-PRF MIL-PRF MIL-PRF Insulation, Electrical, Synthetic Resin Composition, Non Rigid - Yarn, Cord, Sleeving, Cloth and Tape-Glass - Turbine Fuel, Aviation, Grades JP-4 and JP-5 - Fuel, Naval Distillate - Lubricating Oil, Steam Turbine and Gear, Moderate Service - Hydraulic Fluid, Petroleum, Inhibited - Lubricating Oil, Aircraft Turbine Engine, Synthetic Base. NATO Code Number Connectors, Coaxial, Radio Frequency, General Specification for - Hydraulic Fluid, Fire Resistant; Low Temperature, Synthetic Hydrocarbon Base, Aircraft and Missile (See supplement 1 for list of specification sheets.) DEPARTMENT OF DEFENSE STANDARDS MIL-STD-130 MIL-STD-202 MIL-STD Identification Marking of US Military Property - Electronic and Electrical Component Parts - Radio Frequency Connector Interfaces for MIL-C-3643, MIL-C-3650, MIL-C-3655, MIL-C-25516, MIL-C-26637, MIL-PRF-39012, MIL-PRF-49142, MIL-PRF-55339, MIL-C (Copies of these documents are available online at or from the Standardization Documents Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA ) Other Government documents, drawings and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation or contract. NAVAL ENGINEERING STANDARDS (NES) NES 711 NES Determination of the Smoke Index of the Products of Combustion from Small Specimens of Materials - Determination of the Toxicity Index of the Products of Combustion from Small Specimens of Materials (Copies of Naval Engineering Standards are sponsored by the Procurement Executive, Ministry of Defense, ship department, section TE112, block G, Foxhill, Bath 5AB England.) 2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those issues of the documents cited in the solicitation or contract (see 6.2). ASTM INTERNATIONAL ASTM A411 ASTM B3 ASTM B8 - Zinc-Coated (Galvanized) Low-Carbon Steel, Armor Wire - Copper Wire, Soft or Annealed - Conductors, Copper, Concentric-Lay-Stranded, Hard, Medium-Hard, or Soft 3

4 ASTM B33 - Wire, Tinned Soft or Annealed Copper, For Electrical Purposes ASTM B88 - Tube, Water, Seamless Copper ASTM B197/B197M - Wire, Alloy Copper-Beryllium ASTM B211 - Aluminum and Aluminum-Alloy Bar, Rod, and Wire ASTM B286 - Copper Conductors for Use in Hookup Wire for Electronic Equipment ASTM B298 - Wire, Copper, Silver-Coated Soft or Annealed ASTM B339 - Pig Tin ASTM B344 - Alloys For Electrical Heating Elements, Nickel-Chromium and Nickel -Chromium-Iron, Drawn or Rolled ASTM B447 - Tube, Copper, Welded ASTM B452 - Wire, Steel, Copper-Clad, For Electronic Application ASTM B483/B483M - Standard Specification for Aluminum and Aluminum-Alloy Drawn Tube and Pipe for General Purpose Applications ASTM B501 - Wire, Steel, For Electronic Application, Silver-Coated, Copper-Clad ASTM B545 - Tin, Electrodeposited Coatings of ASTM B566 - Wire, Aluminum, Copper-Clad ASTM D470 - Wire and Cable, Crosslinked Insulations and Jackets For ASTM D770 - Standard Specification for Isopropyl Alcohol ASTM D Polyethylene Plastics Extrusion Materials For Wire and Cable ASTM D Standard Specification for Ozone-Resisting Butyl Rubber Insulation For Wire and Cable ASTM D Molding and Extrusion Materials, FEP Fluorocarbon ASTM D Rubber Property-Durometer Hardness ASTM D Standard Practice for Xenon-Arc Exposure of Plastics Intended for Outdoor Applications ASTM D Materials, Molding and Extrusion, Modified ETFE-Fluoropolymer ASTM D Materials, E-CTFE-Fluoroplastic Molding, Extrusion and Coating ASTM D Perfluoroalkoxy (PFA) Fluorocarbon Resin Molding and Extrusion Materials ASTM D Standard Specification for Ozone-Resistant Thermoplastic Elastomer Insulation for Wire and Cable, 90 Degrees C Dry/75 Degrees C Wet Operation ASTM D Standard Specification For Polytetrafluoroethylene (PTFE), Grandular Molding and Ram Extrusion Materials ASTM D Polytetrafluoroethylene (PTFE), Resins Produced from Dispersion (Copies of these documents are available online from or ASTM International, P.O. Box C700, 100 Barr Harbor Drive, West Conshohocken, PA ) IEEE Operations Center IEEE-287 IEEE Standard for Precision Coax Connectors - Standard for Qualifying Class IE Electric Cables and Field Splices for Nuclear Power Generating Stations (Copies of these documents are available online from or from the IEEE Operations Center, 445 Hoes Lane, Piscataway, New Jersey ) 4

5 SAE INTERNATIONAL SAE-AMS-WW-T-700 Tube, Aluminum and Aluminum Alloy, Drawn, Seamless, General Specification For (Copies of these documents are available from the SAE International, 400 Commonwealth Drive, Warrendale, PA , Tel: (inside USA and Canada) or (outside USA), Order of precedence. In the event of a conflict between the text of this document and the references cited herein (except for related associated specifications sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 Specification sheets. The individual item requirements shall be as specified herein and In accordance with the applicable specification sheet. In the event of any conflict between the requirements of this specification and the specification sheet, the latter shall govern. 3.2 Classification of requirements. The classification of requirements for cable are as follows (see table I): TABLE I. Classification of requirements. Requirements Qualification Materials Design and construction Visual and mechanical Operational Marking Weight Workmanship Paragraph Qualification. Cable furnished under this specification shall be products that are authorized by the qualifying activity for listing on the applicable qualified products list before contract award (see 4.6 and 6.3) Reliability. The contractor s reliability program for manufactured cable and procedures shall be in accordance with Materials. Unless otherwise specified (see 3.1), the materials for the principal components of the cable shall be as specified herein. Prior approval to use a substitute material must be obtained from the qualifying activity. When a definite material is not specified, a material shall be used that will enable the finished products to meet the performance requirements of this specification. Acceptance or approval of any constituent material shall not be construed as a guaranty of the acceptance of the finished product Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically and advantageous life cycle costs. 5

6 3.5 Design and construction. Unless otherwise specified (see 3.1), cables shall be of the design and construction specified herein Inner conductors. The inner conductor shall be solid, stranded, braided or helical, bare or coated, as specified (see 3.1). The materials and coatings shall be as specified (see 3.1) Solid inner conductors: a. Bare copper wire. Bare copper wire, soft, or annealed copper wire, shall be in accordance with ASTM B3. b. Tin-coated copper wire. Tin-coated, soft, or annealed copper wire, shall be in accordance with ASTM B33. c. Silver-coated copper wire. Silver-coated copper wire shall be in accordance with ASTM B298, except the thickness of silver coating shall not be less than 40 microinches ( mm). d. Copper-clad steel wire. Copper-clad steel wire shall be high-strength, 40% conductivity, harddrawn, copper-clad, steel wire in accordance with ASTM B452, class 40HS. e. Annealed copper-clad steel wire. Annealed copper-clad steel wire shall have the same requirements as for copper-clad steel wire specified in (d), except shall be annealed. The tensile strength shall be 50,000 lbf/in 2 minimum. f. Silver-coated copper-clad steel wire. Silver-coated copper-clad steel wire shall be in accordance with ASTM B501, class 40 HS or 40A, except the thickness of silver coating shall not be less than 40 microinches ( mm). g. Annealed copper-clad aluminum wire. Annealed copper-clad aluminum wire shall be in accordance with ASTM B566, class 10A or 15A. The thickness of the copper covering shall be 3.5% minimum of the wire radius (8% to 12% by volume) for class 10A, and 5% minimum of the wire radius (13% to 17% by volume) for class 15A. h. Copper-beryllium alloy wire. Copper-beryllium alloy wire shall conform to solution-heattreated, half-hard wire in accordance with ASTM B197/B197M, alloy 172. The tensile strength shall be 110,000 lbf/in 2 to 135,000 lbf/in 2. i. Annealed-copper-beryllium wire. Copper-beryllium alloy wire shall conform to solution-heattreated, half-hard wire in accordance with ASTM B197/B197M, alloy 172. The tensile strength shall be 80,000 lbf/in 2. j. Silver-coated wire. Silver-coating over other wire material shall be in accordance with ASTM B298 with proper correction for the density of the base material when the gravimetric reference procedure is used. k. High resistance wire. High resistance wire shall conform to ASTM B344 (80% nickel 20% chromium). The tensile strength shall be 100,000 lbf/in 2 minimum. The resistance change with temperature shall also be in accordance with ASTM B344. 6

7 Stranded inner conductors. Stranded inner conductors shall be concentrically stranded in accordance with ASTM B8 or ASTM B286. Tensile strength and elongation of conductors shall be tested prior to stranding. Conductors shall not be coated after stranding (no over-coating). Individual wires, before stranding, shall meet all the requirements of the basic wires specified in Diameter tolerances for the completed inner conductor shall be rounded to the next highest.001 inch (0.025 mm) Conductor joints. Joints in individual strands of a stranded wire shall not be closer together than 5 lay-lengths Dielectric cores. The material used in the dielectric cores specified shall be of uniform thickness consistent with the electrical, environmental, physical, mechanical and dimensional requirements (see 3.1). a. Solid dielectric cores. Solid dielectric cores shall be extruded or tape-wrapped and talc-coated when specified (see 3.1). b. Semisolid (air-spaced) dielectric cores. Semisolid, air-spaced dielectric cores shall be constructed in such a manner that air spaces are a basic element of the construction Dielectric core types. The material for the dielectric cores shall be one of the following specified types (see 3.1). The dielectric constant and the dissipation factor shall be consistent with the applicable electrical requirements. a. Type A. Polyethylene (PE) in accordance with ASTM D1248, Type I, Class A, Grade E-4 lowdensity type. b. Type A-1. Solid polyethylene. c. Type A-2. Solid polyethylene coated with the best commercial grade talc, to prevent sticking between individual components of the cable. d. Type A-3. Air-spaced polyethylene. One polyethylene filament thread or a braid of more than one filament threads within a tube of solid polyethylene, or spiraled fins of polyethylene between tubes of solid polyethylene. e. Type A-4. Air-spaced polyethylene, foamed polyethylene. f. Type A-5. Conductive polyethylene shall be in accordance with ASTM D1248, Type I, Class C carbon-black type. The maximum resistance per foot shall be as specified (see 3.1). g. Type D. Not for future design. Dielectric core shall be a composite of three layers of dielectric materials. Each layer shall make intimate contact with each other, except that the outer layer shall be easily strippable. Inner layer: Type H, semiconducting synthetic rubber (see r). Middle layer: Type W, insulating synthetic rubber (see x). Outer layer: Type H, semiconducting synthetic rubber (see r). 7

8 h. Type E. Not for future design. Dielectric core shall be a composite of three layers of dielectric materials. Each layer shall make intimate contact with each other. Inner layer: Type H, semiconducting synthetic rubber (see r). Middle layer: Type W, insulating synthetic rubber (see x). Outer layer: Type Q, insulated polychloroprene rubber, which need not be easily strippable (see w). i. Type F. Polytetrafluoroethylene (PTFE) shall be in accordance with ASTM D4894 and ASTM D4895. j. Type F-1. Solid, extruded PTFE. k. Type F-2. Sold PTFE tape wrapped. l. Type F-3. Air-spaced PTFE perforated tape wrapped. m. Type F-4. Air-spaced PTFE, one PTFE filament thread or a braid of more than one PTFE filament thread within a tube of tape-wrapped PTFE. n. Type F-5. Air-spaced PTFE, porous tape wrapped. o. Type F-6. Air-spaced PTFE, expanded tape wrapped. p. Type F-7. Solid PTFE, coated with a semiconducting material. q. Type G. Not for future design. Solid mineral material (such as magnesium oxide) consisting of finely divided particles free from detrimental impurities which shall be packed tightly under high pressure. r. Type H. Not for future design. Semiconducting synthetic rubber. The volume resistivity of this compound shall be within the range of 100 to 1,000 ohm-cm when tested in accordance with method 9111 in accordance with FED-STD-601, and colored black. s. Type J. Insulating synthetic butyl rubber. Butyl rubber, a copolymer of isobutylene and isoprene, shall be in accordance with ASTM D1352, colored gray. t. Type M. Fluorinated ethylene propylene (FEP) shall be in accordance with ASTM D2116. u. Type M-1. Solid, extruded FEP. v. Type M-2. Air-spaced FEP. Foamed FEP. w. Type Q. Not for future design. Insulating polychloroprene rubber, and colored red. x. Type W. Not for future design. Insulating synthetic rubber. The material shall have a tensile strength of 500 lbf/in 2 minimum and an elongation of 300% minimum in 10 inches in accordance with ASTM D470. 8

9 3.5.3 Outer conductors or extra shields. Outer conductors or extra shields shall be braided or solid (tubular), as specified (see 3.1) Braided outer conductors or shields. Braids shall be applied with the maximum tension possible so as to prevent loosening or creeping but not to cause broken ends. Braids shall have no gaps. Loose strand ends shall be trimmed to within.031 inch (0.79 mm) of the braid and shall lay parallel with the braid. There shall be no splices of the completed braid. The number of braids and the elements of their construction shall be as specified (see 3.1). The individual strands of the braid shall meet the applicable requirements of the basic wires specified in Strands may also be made of galvanized steel wires (see ). The percent coverage specified shall be determined In accordance with the formulas shown below (see 3.1). N P d Percent coverage = (2F F 2 ) X 100%; F = ; a = tan 1 sin a 2π (D + 2d) P C Where: D = Maximum outside diameter of the dielectric core under the braid. In the case of double braid construction, the diameter (D) for determining the coverage of the outside braid shall be the outside diameter of the inner braid. d = Diameter of an individual strand of the braid. N = Number of ends (wire strands) per carrier. C = Number of carriers (separated group of ends) around the diameter of the cable. P = Minimum number of picks per inch (separation points between carriers) along the length of the cable. a = Smaller angle between longitudinal axis of the cable and the braid wires. F = Fill or space factor. For two-conductor cables that are not filled-to-round and not twisted. 2π (D 1 + 2d) P + 4(D 2 D 1 ) P a = tan 1 C C Where: D 1 = Same as D above, except the minor diameter. D 2 = Same as D above, except the major diameter Galvanized steel wire braids. When galvanized steel wire braids are specified (see 3.1) the individual strands shall be soft or annealed, low-carbon, steel wires in accordance with ASTM A411. The tensile strength of the individual strands shall be 50,000 lbf/in 2 minimum. Tin plate (hot-dipped) in accordance with ASTM B339, ASTM B545 may be used as an alternate to galvanize. 9

10 Solid (tubular) outer conductors. Solid outer conductors shall be constructed of metallic tubing, annealed before the final sink. a. Copper-tubing outer conductors. Copper tubing shall be 99% minimum purity. Seamless copper tubing shall be in accordance with ASTM B88. Welded copper tubing in accordance with ASTM B447, fully finished tube with IFR (Internal Flash Removal). The welded copper tubing shall be cold worked and re-crystalized to a uniform grain size throughout the structure with no evidence of the original weld. b. Aluminum-tubing outer conductors. Aluminum tubing shall be 99% minimum purity. Seamless aluminum tubing in accordance with SAE-AMS-WW-T-700, non-seamless aluminum tubing in accordance with ASTM B483/B483M. c. Solid outer conductor joints. Joints shall be within the specified dimensions and tensile strength limits specified for the basic solid outer conductor Barrier tapes. When specified the barrier tapes shall be applied tightly and ride smoothly over the outer conductor (see 3.1). The barrier tape material shall be of the following type: Type FF-2. PTFE tape wrapped. The PTFE may be reclaimed material. Unless otherwise specified (see 3.1). the tapes shall overlap 50% minimum of the width of the tapes Interlayers. When specified the interlayer shall be applied tightly and ride smoothly over the outer conductor (see 3.1). The interlayer material shall be one of the following types: a. Type A-1R. Polyethylene in accordance with ASTM D1248, Type I, Class B, Grade E-4, lowdensity type, and colored red. b. Type C-1. Not for future design. Braid of cotton tapes of 30 denier/2 ply. c. Type K. Polyethylene-terephthalate tape in accordance with MIL-I-631, type G, form T, subform T f, class I, fungus-resistant type. Unless otherwise specified the tapes shall overlap 50% minimum of the width of the tapes (see 3.1). d. Type L. Not for future design. Glass fiber tapes filled with, and uniformly coated with, silicone rubber on both sides and properly cured. Curing may be accomplished after applying the tapes to the conductor. The tapes shall be held from unwinding by being self-bonding, by using a silicone rubber adhesive or by means of a binder over the insulating tapes. e. Type U-I. Not for future design. Urethane elastomer tape. f. Type R-1. Not for future design. Rubber-filled tape. 10

11 3.5.6 Jackets. The jacket material shall be tough, flexible and non-hygroscopic. The jacket shall cover the cable tightly and evenly in a manner consistent with the physical, mechanical, environmental and dimensional requirements. Color shown is for outer surface of jacket. The jacket material shall be one of the following types unless otherwise specified (see 3.1): a. Type IIa. Noncontaminating type of medium-low temperature, plasticized or compounded, polyvinylchloride or polyvinylchloride-acetate meeting the following physical property requirements and colored black: Unaged: Tensile strength: 1500 minimum psi. Elongation: 100%, minimum. After 95.5 hours air oven aging at 100 C: Tensile strength: 80%, minimum of original. Elongation: 60% of original. After oil immersion: Tensile strength: 80%, minimum of original. Elongation: 60%, minimum of original. Brittleness temperature: Unaged: -40 C, maximum. Aged: -40 C, maximum. b. Type IIIa. Not for future design. Polyethylene in accordance with ASTM D1248, type I, class C, weather-resistant type, and colored black. c. Type IV. Polychloroprene rubber, medium-low-temperature type, meeting the following physical property requirements and colored black: Unaged: Tensile strength: 1800 minimum psi. Elongation: 300%, minimum. Set, maximum, inch:.375 (9.53 mm). Tensile stress: 500 (200% elongation, minimum psi). After 95.5 hours oxygen bomb aging at 70 C: Tensile strength: 75%, minimum of original (but not less than 1600 psi). Elongation: 65% of original (but not less than 250 psi). Ozone resistance (After air oven conditioning and 168 At 50 C: No visible cracks..5 hours in ozone). Brittleness temperature: Unaged: -40 C, maximum. Aged: -40 C, maximum. After oil immersion: Tensile strength, 60%, minimum of original. Elongation, 60%, minimum of original. 11

12 d. Type V. Fiberglass braids of the number specified (see 3.1). The braids shall be impregnated with a silicone-base varnish, and oven-baked. The glass fibers shall be in accordance with MIL-Y-1140, class C, and colored brown. e. Type VI. Not for future design. Silicone-rubber-polyester fiber construction. The inner element shall be a single braid of fiberglass impregnated with a silicone-base varnish, under an extruded or tape-wrapped layer of silicone rubber, and the whole thoroughly cured. As an alternate, the inner construction may be a wrap(s) of silicone rubber impregnated fiberglass tape, which shall be fused during processing. Over either construction there shall be a protective braid of polyester fiber impregnated with a high-temperature fluorocarbon lacquer, and colored orange. f. Type VII. Polytetrafluoroethylene (PTFE) shall be in accordance with ASTM D4894 and ASTM D4895, and colored white. g. Type VlIa. Extruded PTFE. h. Type VIIb. PTFE tape wrapped. There shall be two wraps of unsintered tapes applied in opposite directions with an overlap of 50% minimum of the width of the tapes, and the whole fused during processing. i. Type VIII. Not for future design. Polychloroprene rubber, low-temperature type, meeting the physical property requirements as follows and colored black: Unaged: Tensile strength: 1500 minimum psi. Elongation: 300%, minimum. Set, maximum, inch:.375 (9.53 mm). Tensile stress: 500 (200% elongation, minimum psi). Tear resistance: 20 lb/inch, minimum. After 95.5 hours oxygen bomb aging at 70 C: Tensile strength: 75%, minimum of original. Elongation: 75%, of original. After hours air oven aging at 70 C Tensile strength: 80%, minimum of original. Elongation: 80%, minimum of original. Ozone resistance (after air-oven conditioning and 168 At 50 C: No visible cracks..5 hours of ozone). Brittleness temperature: Unaged: -55 C, maximum. Aged: -55 C, maximum. Torsional stiffness ratio: 30, maximum. After oil immersion: Tensile strength: 60%, minimum of original. 12

13 Elongation: 60%, minimum of original. j. Type IX. Extruded fluorinated ethylene propylene (FEP) transparent enough to permit the reading of marking tape through the jacket. k. Type X. Extruded copolymer of ethylene and tetrafluoroethylene (ETFE) shall be in accordance with ASTM D3159. I. Type XI. Extruded copolymer of ethylene and chlorotrifluoroethylene (E-CTFE) type III shall be in accordance with ASTM D3275. m. Type XII. Low-temperature, heat and weather resistant polyurethane thermoplastic elastomer, meeting the following physical property requirements: Unaged: Tensile strength: 3500 minimum psi. Elongation: 550%, minimum. Set, maximum:.250 inch (6.35 mm). Tensile stress: 550 (100% elongation, minimum psi). Tensile stress: 1000 (300% elongation, minimum psi). Tear resistance: 90 lb/inch, minimum. Durometer: 82 "A" maximum points. After 20 1 hours air pressure aging at 127 C: Tensile strength: 50%, minimum of original. Elongation: 50% of original. Ozone resistance (after air-oven conditioning and 168 At 50 C: No visible cracks..5 hours in ozone). Brittleness temperature: Unaged: -55 C, maximum. Aged: -55 C, maximum. Torsional stiffness ratio: 35, maximum. Torsional modulus at -55 C: 20,000 maximum PSI. Hydrolytic stability: Tensile strength: 50% minimum of original. Elongation: 70% minimum of original. Durometer: 8 "A" maximum points change. n. Type XIII. Perfluoroalkoxy (PFA) shall be in accordance with ASTM D3307, type 1 having a tensile strength of 3,000 lbf/in 2 and a minimum elongation of 275%. o. Type XIV. Cross-linked polyolefin. 13

14 p. Type XV. Styrene block copolymer or equivalent thermoplastic elastomer (TPE) shall be in accordance with ASTM D Armor. Metal armoring shall be of a braid construction that is rugged, tough and flexible. a. Braid. Individual braid wires No. Alclad 5056 aluminum-alloy shall be in accordance with ASTM B211. The diameter shall be inch ( 0.32 mm ± mm) and the tensile strength shall be 52,000 lb f /in 2 minimum, before application onto the cable. The percent coverage shall be 88% minimum. The formulas shown in shall be used to determine the percent coverage of the braid construction. b. Paint. Armor covered with an aluminum paint, paste form, and colored light green and produced prior to 8 January 1996 may be used only until existing stock is purged. 3.6 Visual and mechanical inspection. When cables are examined and tested as specified in 4.8.1, the visual and mechanical characteristics shall be as specified (see 3.1) Diameter measurements. When cables are examined as specified in , the diameter measurements shall be as specified (see 3.1) Out-of-roundness of jacket measurements (when specified, see 3.1). When cables are examined as specified in , the out-of-roundness of the jacket diameter dimensions shall be as specified (see 3.1). The dimensions shall be as specified in the detailed specification and out-ofroundness (the difference in diameter dimension in mutual perpendicular planes at any cross section) shall not exceed 50% of the difference between minimum and maximum diameters specified Eccentricity of inner conductor. Not applicable to cables that have the inner conductor formed over an inner conductor support. When cables are examined as specified in , the displacement of the inner conductor shall not exceed 10% of the core radius, unless otherwise specified (see 3.1) Adhesion of conductors. When cables are tested as specified in , the adhesion or the inner conductor to the dielectric core and the adhesion of the dielectric core to the outer conductor shall be as specified (see 3.1). 3.7 Operational. Unless otherwise specified, the operational requirement shall be as specified herein (see 3.1) Continuity. When cables are tested as specified in 4.8.2, each conductor and shield shall be continuous Spark test. Not applicable to semirigid cables or to cables with type V and type VI jackets. When cables are tested as specified in 4.8.3, there shall be no breakdown, flashover, or sparkover Voltage withstanding. When cables are tested as specified in 4.8.4, there shall be no breakdown, flashover, or sparkover Insulation resistance. When cables are tested as specified in 4.8.5, the insulation resistance per 1,000 feet shall be as specified (see 3.1) Corona extinction voltage. When cable test specimens are tested as specified in the corona extinction voltage shall be no less than that specified (see 3.1). 14

15 3.7.6 Characteristic impedance. When cables are tested as specified in 4.8.7, the maximum characteristic impedance shall not exceed the higher value specified, and the minimum shall not be less than the lower value specified (see 3.1) RF transmission loss (attenuation). When cables are tested as specified in 4.8.8, the RF transmission loss shall not exceed the values specified over the frequency range or at the frequencies specified (see 3.1) Standing wave ratio (return loss). When cables are tested as specified in the standing wave ratio (return loss) shall be within the specified limits over the specified frequency range (see 3.1) Capacitance. When cables are tested as specified in, the maximum capacitance shall be as specified (see 3.1) Capacitance stability. When cables are tested as specified in , the capacitance during and after the test shall not have changed from its initial measurement more than the specified value (see 3.1) Capacitance unbalance. For two-conductor cables only. When cables are tested as specified in , the capacitance unbalance shall not exceed the specified value (see 3.1) Transmission unbalance. For two-conductor cables only. When cables are tested as specified in , the transmission unbalance shall not exceed the specified value (see 3.1) Mechanically induced noise voltage. For low noise cables only. When cables are tested as specified in , the mechanically induced noise voltage shall not exceed the specified value (see 3.1) Time delay. When cables are tested as specified in , the time delay shall be as specified (see 3.1) Aging stability. Not applicable to semirigid or cables with type IX jackets. When cables are tested as specified in , there shall be no evidence of cracks, flaws, or other damage in the jacket material Stress-crack resistance. FEP jacket. Unless otherwise specified (see 3.1), cable shall be tested as specified in There shall be no evidence of cracks, flaws or other damage in the jacket material Outer conductor integrity. Only semirigid cables. When cables are tested as specified in , there shall be no evidence of cracks, flaws, or other damage in the outer conductor material Cold bend. Not applicable to semirigid cables. When cables are tested as specified in , there shall be no evidence of cracks, flaws, or other damage in the jacket material of flexible cables or the dielectric core material of flexible cable Dimensional stability. Not applicable to time delay cable and cables with braided inner conductor. When cables are tested as specified in , the measurement at each end shall not exceed the specified value (see 3.1) Contamination. PVC type lia jacket cable only. When cables are tested as specified in , the delta Q shall not exceed

16 Bendability. Semirigid cable only. When cables are tested as specified in , there shall be no cracks, splits, fracturing, wrinkling, or other damage in the solid outer conductor material, after being formed around the mandrel diameter specified (see 3.1) Flammability (when specified see 3.1). When cables are tested as specified in , the rate of travel of the flame shall not exceed 1 inch per minute and cable surface shall not flame for more than 1 minute after the gas flame is withdrawn. There shall be no flaming of the tissue as a result of incendiary drippings from the specimen Flame propagation (when specified see 3.1). Samples of completed cable, when tested in accordance with , shall be self-extinguishing and shall not burn to the top of the tray Acid gas generation. When cables are tested as specified in , the acid equivalent shall not exceed the percentage, by weight of the sample, as specified (see 3.1) Halogen content. When cables are tested as specified in , the halogen content shall not be greater than specified (see 3.1) Immersion tests. When cables are tested as specified in , the tensile strength and elongation shall be no less than that specified (see 3.1) and there shall be no evidence of cracks, flaws, or other damage to the jacket material Smoke index. When cables are tested as specified in, the smoke index shall not be greater than that specified (see 3.1) Toxicity Index. When cables are tested as specified in , the toxicity index shall not be greater than that specified (see 3.1) Durometer hardness. When cables are tested as specified in , the hardness shall be as specified (see 3.1) Weathering. When cables are tested as specified in , the tensile strength and elongation shall be no less than 75% of their un-weathered values (see 3.1). The surface shall exhibit no signs of cracking when examined using 3X magnification Abrasion resistance. When tested as specified in , failure shall be construed if electrical contact occurs between either abrading element and the specimen conductor (as evidenced by cessation of cylinder rotation) prior to completing the specified number of abrasive scrapes (see 3.1). Test must be conducted on no fewer than 5 specimens Tear strength. When tested as specified in , the percentage heat distortion shall be no greater than that specified (see 3.1). Test must be conducted on no fewer than 6 specimens Heat distortion. When tested as specified in , the percentage heat distortion shall be no greater than that specified (see 3.1) Physicals (aged). When tested as specified in , the specimens tensile strength and elongation shall not be less than that specified (see 3.1) Tensile strength and elongation. When tested as specified in , the cable jacket shall have a tensile strength and elongation no less than that specified (see 3.1). 16

17 Inductance. When cables are tested as specified in the inductance value shall be as specified (see 3.1). 3.8 Marking. Cables shall be marked with the PIN, defense specification number, manufacturer s code symbol or name, (date code to be marked on the rest of the cable as a minimum) in accordance with the basic requirements of MIL-STD-130. The marking shall be done in such a manner as not to permanently indent, deform or otherwise damage the jacket or outer covering. The marking shall be visible and legible from the outside of the cable, except for armored cables. The marking shall be legible after the aging stability and stress crack resistance tests. The following details shall apply: a. Armored cables. Armored cables shall be marked at Intervals not exceeding 6 inches by inserting a suitably printed tape under the armor or jacket providing the marking is legible after the cable construction is completed. When the armor is added to a cable that has been previously marked with its unarmored type designation, the marking tape shall be inserted between the armor and the jacket only. When cables are so double marked, the marking on or under the jacket shall be disregarded. b. Unarmored cables. (1) Types lia, IIIa, IV, VI, VIII, XIV and XV jackets shall be surface marked at intervals not exceeding 2 feet. Cables with type V jackets shall be marked with tapes or surface marked in ink. Cables with type VI, X, and XI jackets may be optionally marked with tapes in lieu of ink. (2) Types IX and XIII jackets shall be marked at intervals not exceeding 6 inches with marker tape, with a reversal of the marking tape permitted every 6 inches, or surface marking (surface marking shall not be reversed). For cables (types IX and XIII jackets) having a nominal outside diameter of.150 inch (3.81 mm) or less the method of marking shall be at the manufacturer s discretion, but with the qualifying activities approval and the marking as minimum must reflect the manufacturer s CAGE code. If additional marking is possible, the remainder of the required marking shall be applied. (3) Cables, twin axial, which do not have a requirement for fill-to-round, may be marked with a tape under the jacket regardless of jacket type. c. Semirigid cables and unarmored cables with type VII jackets need not be marked. 3.9 Weight. When cables are tested as specified in , the maximum weight of completed cable construction shall be as specified (see 3.1) Workmanship. All cables shall be manufactured and processed in such a manner as to be uniform in quality and shall be free from any burrs, die marks, chatter marks, foreign material and other defects that will affect life, serviceability, or appearance. Workmanship shall be such as to enable the cable to meet the applicable requirements of this specification. 17

18 4. VERIFICATION 4.1 Classification of inspection. The inspection requirements specified herein are classified as follows: a. Materials inspection (see 4.4). b. Final inspection (see 4.5). c. Qualification inspection (see 4.6). d. Conformance inspection (see 4.7). 4.2 Reliability assurance program. A reliability assurance program shall be established and maintained. Process control records shall cover the implementation of devices such as control charts (e.g., X bar and R charts) or other means of indication of the degree of control achieved in the production process. Records shall also indicate the action taken when each out-of-control condition is observed, and the disposition of non-conforming products processed during the period of out-of-control operation. Records associated with non-conforming products shall be kept for a minimum of 3 years. Evidence of such compliance shall be verified by the qualifying activity of this specification as a prerequisite for qualification and continued qualification. 4.3 Inspection conditions. Unless otherwise specified herein, all test inspection conditions shall be performed in accordance with the test conditions specified in MIL-STD-202, as follows: a. Temperature: 25ºC 10ºC. b. Relative humidity: 60% 15%. c. Atmospheric pressure: 725 mm 76 mm of mercury. 4.4 Materials inspection. Materials inspection shall consist of certification supported by verifying data that the materials listed in table II, used in fabricating the cables, are in accordance with the applicable referenced specifications or requirements prior to such fabrication. 18

19 TABLE II. Materials inspection. Material Ethylene tetrafluoroethylene (ETFE) Ethylene chlorotrifluoroethylene (E-CTFE) Fiberglass Fluorinated ethylene propylene (FEP) Paint, aluminum Polyethylene (PE) Polytetrafluoroethylene (PTFE) Polyolefin, cross-linked Rubber, butyl, insulating synthetic Rubber, insulating synthetic Rubber, polychloroprene Rubber, synthetic, semiconductor Tape, polyethylene-terephthalate Tubing, aluminum, seamless Tubing, copper, seamless Wire, aluminum-alloy (alclad 5056) Wire, aluminum, copper-clad Wire, copper, bare Wire, copper, beryllium (alloy 172) Wire, copper, silver-coated Wire, copper, tin-coated Wire, high resistance Wire, steel, copper-clad Wire, steel, copper-clad, silver-coated Wire, steel, galvanized Rubber, polyurethane Stranded inner conductors Copper conductors for use in hook-up wire for electronic equipment Requirement paragraph 3.5.6k 3.5.6l 3.5.6d t 3.5.7b a 3.5.6f 3.5.6o s x 3.5.6a,c,e,i r 3.5.5c b a 3.5.7a g a h c,j b k d f m Applicable documents ASTM D3159 ASTM D3275 MIL-Y-1140 ASTM D ASTM D1248 ASTM D4894 and ASTM D ASTM D1352 ASTM D FED-STD-601 MIL-I-631 SAE-AMS-WW-T-700 ASTM B88 ASTM B211 ASTM B566 ASTM B3 ASTM B197/B197M ASTM B298 ASTM B33 ASTM B344 ASTM B452 ASTM B501 ASTM A ASTM B8 ASTM B286 19

20 Inspection TABLE III. Final inspection. Semirigid cable 1/ All other cable 2/ Requirement paragraph Method paragraph Continuity Voltage withstanding Continuity Spark test Voltage withstanding Insulation resistance Out-of-roundness of jacket measurements / Sampling and inspection shall be in accordance with / Tests performed on each continuous length of cable. 4.5 Final inspection. Prior to the delivery of the cable, the tests in table III shall be performed, as applicable Failure. a. Semirigid cable: One or more failures shall be cause for refusal of the lot. b. All other cable: One or more failures shall be cause for refusal, except a spark test failure may be repaired or the cable length cut out. 4.6 Qualification inspection. Qualification inspection shall be performed at a laboratory acceptable to the Government (see 6.3) on sample units produced with equipment and procedures normally used in production. Group qualification shall be as specified in the appendix to this specification Sample. The sample of each cable type submitted for qualification inspection shall be of sufficient length to perform all the applicable tests in table IV Inspection routine. The samples shall be subjected to the inspections specified in table IV. The entire sample shall be subjected to the inspections of group I. The specimen length shall be cut from each sample as required, and subjected to inspections of group II Failure. One or more failures shall be cause for refusal to grant qualification approval. 20

21 TABLE IV. Qualification inspection. Inspection Group I Number of specimens to be tested Requirement paragraph Test method paragraph In-process inspection Continuity Spark test Voltage withstanding Insulation resistance 1/ Visual and mechanical inspection Physical dimensions Marking Workmanship Entire sample Entire sample Entire sample Entire sample Entire sample Entire sample Entire sample Entire sample Entire sample Group II Corona extinction voltage 2/ Characteristic impedance RF transmission loss (attenuation) 2/ Standing wave ratio (return loss) 2/ Capacitance 2/ Capacitance stability 2/ Capacitance unbalance 3/ Transmission unbalance 3/ Inductance 3/ Mechanically induced noise voltage 4/ Time delay 2/ Aging stability 5/ Stress-crack resistance 2/ Outer conductor integrity 6/ Cold bend 9/ Dimensional stability 7/ Contamination 8/ Bendability 6/ Flammability 2/ Flame propagation 10/ Acid gas generation 10/ Halogen content 10/ Immersion 10/ Smoke index 10/ Toxicity index 10/ Durometer hardness 10/ Weathering 10/ Abrasion resistance 10/ Tear strength 10/ Heat distortion 10/ Physicals (aged) 10/ Tensile strength and elongation 10/ Weight See footnotes on next page

22 TABLE IV. Qualification inspection - Continued. 1/ Not applicable to solid types A and F dielectric cores. 2/ When specified. 3/ Applicable to two-conductor cables. 4/ Applicable to low noise cables. 5/ Not applicable to semirigid or cables with type IX jackets. 6/ Applicable to semirigid cables. 7/ Not applicable to time delay or braided inner conductor cables. 8/ Applicable to type IIa jackets. 9/ Not applicable to semirigid cables. 10/ Applicable to type XIV, polyolefin jacketed cables only Retention of qualification. To retain qualification, the contractor shall forward a report at 12-month intervals to the qualifying activity. The qualifying activity shall establish the initial reporting date. The report shall consist of: a. A summary of the results of the tests performed for inspection of product for delivery (groups A and B), indicating as a minimum the number of lots that have passed and the numbers that have failed. b. A summary of the results of tests performed for qualification verification inspection group C, including the number and mode of failures. The summary shall include results of all qualification verification inspection tests performed and completed during the 12-month period. If the summary of the test results indicates nonconformance with specification requirements, and corrective action acceptable to the qualifying activity has not been taken, action may be taken to remove the failing product from the qualified products list. Failure to submit the report within 30 days after the end of each 12-month period may result in loss of qualification for the product. In addition to the periodic submission of inspection data, the contractor shall immediately notify the qualifying activity at any time during the 12-month period that the inspection data indicates failure of the qualified product to meet the requirements of this specification. In the event that no production occurred during the reporting period, a report shall be submitted certifying that the company still has the capabilities and facilities necessary to produce the item. If during three consecutive reporting periods there has been no production, the manufacturer may be required, at the discretion of the qualifying activity, to submit representative cables of each type to testing in accordance with the qualification inspection requirements. 4.7 Conformance inspection Inspection of product for delivery. Inspection and final inspection in accordance with table III of product for delivery shall consist of groups A and B inspections Unit of product. A unit of product shall be 5,000 feet of cable of the same type designation. If a production run is less than 5,000 feet, then the quantity produced shall be one unit of product Inspection lot. The inspection lot shall consist of the number of units of product, offered for inspection at one time. All of the units of product in the inspection lot submitted shall have been produced during the same production period with the same materials and processes Sample unit. A sample unit shall be a unit of product selected at random from the inspection lot without regard to quality. 22